Method of erecting hydrocarbon conversion apparatus



Sept. 13, E' V. BERGSTROM METHOD OF ERECTING HYDROCARBON CONVERSION APPARATUS Filed Deo. 9, 1950 HERE/fk E6 12 ff HOT CT/.YST S10/maf HEI/,grap l IFT PUT INVENTOR 512' Fefgslrwn/ BMU 65N T 0f? ATTORNE United States Patent g 1METHOD' 0F. ER'EGTINGHYDRUCARBON CONVERSION y`.APPARATUS Eric V."Bergstrom,-'Shortrliiills, N.`I.,assignor to Socony Mobil Oil Company; Inc., a. corporation of New' York :Application December 9, 91950, Serial' N o. 199,996 'zclai'ms (C1.` 29,4zs)

;This .invention isldirected tom-hydrocarbon conversion systemzand methodof erectingsuchla system. lt is more `:particularly:fdirected toacatalytic cracking system of 'i smallwsize and Ieconomical erection.

:It -isnw'ell known fin the petroleumartto'convert suitably prepared 'hydrocarbonsstor moreidesirable products by f bringing fthern,:: at'suitable; conditions .of temperature and #pressure intocontact with/an .adsorbent `particle-form Y A material. I'Ehese1conversionuprocesses are knownaspoly- :.merization,. alkylation, fdesulfur-ization,tdehydrogenation, :cyclization, hydrogenationand vcatalytic cracking. 1 By far the-:mostimportant process,-at `leastgat present, is the 2,7 17,439 atented Sept. 13, 1955 present economy, :is exceedinglyeexpensive. AfterY vthe erection zof the rigging, lfthestructure f for` the cracking system is commenceduadjacentf theretoand the unit` built fromthe bottom( up. fTheLvessels--aregassembled piece by piece in the field during erection andinplace. jAfter the Acompletionofthe unit, ithe 'ifigfgingtusedV during erection Vmust bedismantled and-fremovedto the location of the next cracking systexn whichmay beadistanceof hundreds of miles. 10'

= `In kthe-lpetroleum'findustryicm-legged;pyramid-shaped derricks are availablefinrmany sizesbbetween 100-200 lfeetI tall. .Thesestructures are ordinarily-mountedover well drilling "equipment, designedwprimarily to support the drill rod as it boreseintotheeathinvsearch for oil. These. structures.` are:k available corrixrierciallyl at an economical :pricepbecause of thel'miracle of -mass production lFor example-:theycanbefobtainedf in sizes 189 ft., 178V- ft., elAOrtft., 1`1'36iwft., 129-'ft., and Y 122 lit. tall -from the'oor'zlevel tothefcrownlblock beam. The crown block' beams are horizontally1 located atltheE top of` the -zderrick andare adapted to-supporta heavy crown block or. series of L sheaves"l fon use -in-1supporting the drill rod. Around the crown block beams is attache'dqafproi fftected'platformiknown as-:thelwa-tentable. l'The aperture r-waterf .tableiopeningL Somepof. fthe'V larger sized fderricks .catalyticcracking of heavy hydrocarbons ,inthe presence of a::par,ticlefor1nadsorbent'toiproducel lighter .hydro- :carbonsdnithegasoline:boilingrange. .Byzthis expedient, portions of the crude.;oil,;aftenihegstraight:run gasoline hasrl been removed, arre1cracke'd'- tot produceY .an increased n :yield` of gasoline 'In addition tonincreasingi-the yield: of gasoline from eachbarrelof crude,: the catalytic;cracking-lprocessphas the added advantagethatthe gasoline :producedrgenerally has ahigher octane-.,number. f-This'fueleis thus .moreyattractive for. -use inehigh .compression :internal combus- -tion engines to prevent undesirablejknocking :orfdetonation. flnternal .combustion engine4 compression ratios have@ gradually `increased over; `the years, necessitating-,- a fuel of'increasingoctane-number. The-'current high corn- Ypression engines.and.zthose rtojbe produced in `the Vlnear future have caused.th e' -fuel octanernurnber require- `ments tov-reach unprecedented levelsand thisdernand is beingrnet, by thelarge renners? atleast; :by thefincreased f useofx catalytick crackingsystems. Thishas resultedin :an :octane race amongsthe; petroleum `reiners;in lwhich small, aswell. asdarge refiners .must .compete successfully. `.Present commercial ...catalytic .creacking .s systems .are large, tailor-mademnits oftabout,10,()00?15,000l and even approaching 50,000barrels. per -stream day. .At these kthe :heavy crown.`v block,:into: positionlfinf'the'-water Ktable opening. `The; prefabricatedszparts:ofl :the derrick areassembled rapidly:inthefieldrby=bo1ting1or riveting-thelparts together. The'four angle'uirom legsareibraced by-ap `propriate':horizontal and angular/braces which`fo`rm-so called-npanels. i @nl-floue side fof 'thefderrickfthef=bracing members at athebottomz'are; so .arranged that. an enlarged inverted V-shapedtfopeningiisl.left throughi.whichobjects can-be; `sucked rinto 'theiderrick Structure. f'lf the' load on :thefderrick'fis fhigh,:the= legs :can-.be braced or. stiff-legged by the addition of casing which is bolted intofthe inside vided -forathat :purpose: s

,L One' favored system `of hydrocarbonconversion requires elongatedyerticalfvessels,#known asfthereactorand Ithe kiln, through which substantially compactvcolurnnsfy of outputs,..theexpense. fof.. piecemeal.ielderection can' be met andthe .cost` paid- .out ina. reasonable andpractical period ottime. :.Whenlheseunits, are/scaled ,dowm :however, .to vprovide systems having L avcapacity.'-of 4about bulk .of -small-renersp-.the.excessive `cost of; piecemeal erection ati-thersite'offthe structure becomes prohibitive, andtalthoughsmallrefiners .must havev crackingl capacity forvsurvival, they, cannotleobtain =it, -at present, -in the Vsmall*V sized units becauseofithe,exorbitant.cost. W11en thevesselsare scaledrfdown--in-v size, itheyfarernot found f to be,iproportionatelyf':lessexpensive. `Ingaddition, erection, costs; in :the :field-t. varyonlyf-slightlyxwith.l difference in size; of lthe Vunits-erected. @"Present` erection procedure requiresithe amovingqinto: positionnof a? ylarge amount or .expensive.rigging,- for=.example,$25;000 worth or more. V:This frigginguwhichegenerally xincludes .t a ginLpole capable eof sliftngheavy bulkyobjects ftofhigh; elevation, .is :erected :by;eld-crews.-broughtrftogathe; erectionfsite.` Itis corn- :mon vknowledge:that-:such: acuse -of skilled? labor in =our the rsurface.

`particle-form'catalyst','are5gravitated. Ii1 this` movingbed v4process the particles areggravitated throught the'reactor wherein they are contacted with a suitably preparedchargingstockr at aftemperature; andapressure appropriate for the desired conversion. kThe` converted hydrocarbons are gcontinuously vwithdrawn.'.from'ithe:vessel and transported .gravitated fromwthevsurgervesselfrthrouglr antappropriat'ely shaped,1 elongated-ife'ed-e. conduit: or" legdownwardly into `theftop o-,the4 reactor. f-The feedvlegperrnits-thefintroduction of y'the -catalyst-lintothe reactor, against the advanced `pressure Imain-tained ltherein.wvvitlioutfgthe use-onvalves bor seals of a mechanical type. Although less preferred, it is sometimes desired to operate the kiln at a greater or the same pressure as found in the reactor. In this case the kiln may be located above the reactor, with the gravitating feed leg attached to the top of the kiln. When little or no pressure differential is used between the vessels the feed leg can be short and hence the structure materially reduced in height.

The contact particles may partake of the nature of natural clays, treated clays or synthetic associations of silica, alumina or silica and alumina or chromia, any of which may have other constituents added, such as certain metallic oxides. or irregular in shape, but regular shapes are preferred, such as, spheres or beads, pellets, pills, etc. The size may range from 3-60 mesh, Tyler Screen Analysis, but may preferably range 4-15 mesh.

These particles may be regular,

When the vessel size is limited to about l2 ft. diameter sembly. Therefore, by limiting the vessels to a size maxi- V;

mum which is transportable by rail from the fabrication factory to the erection site, a substantial saving can be effected.

This invention proposes, broadly, the erection of a standard oil well derrick, with only minor modifications, at the site of a moving bed system. The vessels and parts of the system are all shop fabricated and shipped to the site as units by rail. The derrick is n`rst used as the erection rig, in that the parts Vof the moving bed system are sucked in through the inverted-V opening and hoisted upwardly into the structure. The parts are locked in place in the structure end, therefore, the derrick serves the dual purpose of the erection rigging and the moving bed system support means. By this procedure a substantial saving is eifected over the cost of a moving bed system scaled down to the size of the unit above described, but assembled in the former manner in tailor-made fashion.

The object of this invention is to provide a simplified moving bed system of catalytic cracking. Y

It is a further object to provide a package-type moving bed catalytic cracking system within the price range of small refiners.

It is a further object to provide a simplified method of assembling a moving bed catalytic cracking system.

These and other objects will be made apparent in the following description, read in conjunction with the attached drawing.

Figure l is a diagrammatic sketch of a simplified package-type moving bed catalytic cracking system assembled.

Figure 2 is a plan view of a cross section of the system shown in Figure l as seen on planeV 2 2 of Figure l.

Figure 3 is a fragmentary view of the top of the system shown on Figure 1 and indexed 90 degrees from the view of Figure l.

Referring to Figure l, the footings 10 are first installed, preferably deep enough to reach a firm bed rock. The parts of the derrick are bolted together from the bottom up, the first pieces being placed in position by means of a small gin pole mounted adjacent the derrick structure, and subsequent pieces being located by a gin pole attached to the derrick structure which is moved up as the work progresses. The A-frame 11 is mounted atop the derrick and the hook 12 is attached. The A-frame and hook are adapted to support the sheaves and rigging used in erecting the moving bed system. The derrick is then modified by the vaddition of cross-members, such as I beams 13, 14, to provide a transverse mount for the reactor and kiln. The legs,15, or at least one of them, are reinforced or stiff legged up to thelevel of the top cross beam 13, by bolting o1 Welding reinforcing means, usually tubular casing, into the angle of the legS- This PTO' 4 vides additional support for the heavyrmoving bed and the system vessels.

The reactor 20, kiln 21, separator 22, and related parts of the moving bed system are all fabricated and assembled in factories under conditions which make the fabrication economical. These completely assembled vessels are then shipped by rail, as units, to the site of erection. The reactor 20 is introduced through the inverted V-window at the bottom of the derrick and hoisted upwardly to its support position on the cross-beams 13. The kiln 21 is then introduced into the derrick in the same manner and located on cross-beams 14. The lift pot 23 is mounted in a centrally located place and the related conduits are built up, generally from the bottom upwardly. The lift pipe 24 and feed leg 25 assembly is stopped near the top and the separator 22 is lifted into position. The lift pipe 24 and feed leg 25 can then be completed up to the separater 22. The gin pole 11 and hook 12 are left in position for servicing the unit after the installation of the system is complete. Therefore, there is no rigging to dismantle and remove at the conclusion of the assembly. Related vessels and piping can be quickly connected to the system and the unit placed immediately on stream.v

It is seen that, by following the above indicated techniques and erection procedure, the cost, and particularly the field costs, are greatly reduced. The erection time is materially reduced, placing high octane gasoline in the hands of the small rener at the earliest time after decision to build, thereby helping him to hold his position in the race to high octane motor fuel. In the present highly competitive fuel market this may be an exceedingly important factor for the small refiner requiring a unit of about G-6000 bbls. per stream day.

As an illustration, a 189 ft. standard derrick is selected having a 38 ft. 6 in. square base, 17 ft. gin pole atop the structure,and a water table opening of 7 ft. 6 in. The V-window has a clearance of 27 ft. 7% in. at the center. The gin pole has a vertical'lifting capacity of 20,000 lbs., which is adequate for the loads involved in erecting the vessels and piping of the moving bed system. The kiln may conveniently be l2 ft. in diameter x 37 ft. 8 in. long, and the reactor may conveniently be l0 ft. in diameter by 34 ft. 6 in. long. The cross beams are appropriately placed at about 88 ft. and 45 ft. elevations and the reactor and kiln are lifted and locked in place. The kiln supports a catalyst cooler below it for cooling the catalyst withdrawn from the kiln. The lift pot is installed and the conduits built up to an elevation somewhat below the top of the derrick. The separator may be a vessel of about 7 ft. diameter and 24 ft. long. This vessel is lifted into place so that a substantial portion of the vesselprojects through the water table opening under the gin pole. The conduits are then completed and the external vessels and pipes are connected into the system.

it is seen that there results a feed leg about 50 feet long, which, When properly shaped, can introduce catalyst into the reactor against a pressure diiferential of about l0 pounds per square inch. It is desirable to operate the kiln near atmospheric pressure to avoid expensive gas pumping equipment and gas sealing means. When the pressure differential between kiln and reactor is small, as in the less preferred form of operation, the feed leg can be reduced, and hence, the smaller derricks, such as, for example, foot derrick, can be used. A satisfactory catalyst circulation rate is found to be about 80-90 tons per hour, and hence, the lift pot and lift leg are designed to provide this flow. A hot catalyst storage vessel may be suitably mounted adjacent the derrick having a diameter of about l2 ft. and length of about 95 ft., as indicated by detail 30 on Figure l. When valve 31 is opened, catalyst from the separator feeds into the hot storage vessel 30 through the conduit 32. When the valve 33 is opened, the catalyst is returned from the hot storage vessel to the lift pot 23 through the conduit 34. A fresh www catalyst is needed'the vlve36 is openedallowingcatlyst to feed through.Itheroi'lduit37it r1the=-elevator 38. The

catalyst Vdischar-ges;fiom\^t`lie 1tppfofftheaeleyatorvthrough i :the: conduit 39fzintoflthe conduit 34,:.thereby1aeaehing the lift pot 23. .TheffreshfzcatalystvesselsSSseanfibe:filled byusing :the elevatore; whichimgy: -sllitablylhe aflO ton perrhourfbueket type econveyoigvto iintroduce catalyst-into the top of the vessel through the conduit 40.

When processing a crude which deposits large amounts of carbon on the surface of the catalyst, a larger regeneration vessel may be required than the maximum prescribed hereinbefore. The increased burning capacity can be provided by using two kilns in parallel arrangement. Referring to Figure 2, a plan view of the derrick as seen on plane 2 2 of Figure 1, the two kilns 21 are shown in side by side relationship. It has been found desirable to have the lift pipe of gas lifts adapted for raising granular contact material substantially vertical and straight.-

Hence, the lift pipe is centrally located in the derrick as shown on the Figure 2. The corners of the derrick are referred to as bays. In Figure 2, therefore, two bays are occupied by the kilns and a third bay is occupied by the stair well. This leaves an empty bay through which repair and replacement parts can be lifted. Figure 3 shows a front view of the top of the derrick and the gin pole, as seen from a position indexed 90 degrees from the View in Figure l. The hook 12, as previously indicated, is left in position after assembly. A guide sheave 40A or series of them is used to route the cables around the separator, and into the open bay so that loads can be lifted to any desired level. It is seen therefore that the shape of the derrick is ideal as a support structure for the simplified or package-type moving bed catalytic cracking system. The lower wide base provides ample space for the kiln and reactor, which are mounted near the ground. The empty bay provides working space in the structure, Whereas, in the former moving bed systems, rigging had to be built alongside the unit when repairs or exchange of parts was required.

These package-type moving bed cracking systems may range in size from 1000-6000 barrels per stream day and preferably 1500-3000 barrels per stream day. The kiln and reactor both may range 10-12 ft. diameter by 35-50 feet long. Using the larger sized kiln, the burning rate will be approximately 1600-2000 pounds per hour of coke. Hence, when the burning demand is greater than 1600-2000 pounds per hour, two kilns must be used in parallel circuits. The 189 foot derrick is found to be suitable for all simplified moving bed systems now contemplated; however, smaller derricks can be used for smaller cracking systems. The support strength of the standard 189 foot derrick is approximately 1,000,000 pounds. The weight of the largest package-type moving bed system including catalyst is approximately 1,000,000 pounds. vThe 12 foot diameter vessel is substantially the largest vessel that can be used without displacing the centrally located lift pipe. As previously indicated, it is desirable to keep the lift pipe in the center. Hence, this adds a further limitation on the size of the vessel.

Approximately one-third of the time required for setting up a moving bed system is saved by using the method of erection herein disclosed when erecting a moving bed 6 catalytic cracking system of equivalent size. There results an overall saving of about $100,000 for a 3000 barrel per stream day unit built as hereinbefore disclosed over building a 3000 barrel per stream day unit in the former manner. This saving is sufficient to enable the small reiiner to produce cracking capacity at a reasonable and economical price, thereby preventing the small refiners from being forced out of business or into combination with other refiners as a result of the present highly competitive octane race.

c Thelabove-indicated examplesareineludedioaegtplanatory purposes and are not intended to limittthegscope of the invention. The only limitations intended are those found in the followiiigclaims.

5 What is claimedis: t

l. The method of erecting a simplified moving bed @hydrocarbon crack-ing system whiehfcomprises-'erecting a f"-well lderrick,i comprised-of-f-rame means' defining-airspace -of'-aeross sectional-area -that ifdeereases vwithfliieigh aesup'port *member to thergin-po`le,a'ttai`ching` substantially horizontal ksupporting means to the derrick,` inV the lower section thereof adapted to support a reactor, stiff-legging at least one of the legs 0f the derrick `up to the level of the horizontal support means, introducing a-prefabricated reactor through one of said frame means near the bottom thereof, hoisting said reactor within the derrick by means of rigging attached to the support member to said horizontal support means, supporting said reactor from said 20 support means, said reactor being located in one corner of the derrick, attaching a second substantially horizontal supporting means to the derrick in the lower section thereof adapted to support a kiln, similarly introducing and hoisting a prefabricated kiln within the derrick by means of .rigging attached to the support member to said second horizontal support means, supporting said kiln from said support means, said kiln being located in the same corner of the derrick as'the reactor at a level below the reactor, locating a lift pot at the bottom of the derrick in a central location, building a lift pipe from prefabricated sections upwardly from the lift pot to a location near t the top of the derrick, connecting Ythe bottom of the reactor and top of the kiln with a communicating conduit, connecting the bottom of the kiln and the lift pot with a communicating conduit, building a gravity feedA leg above the reactor to a location near the top of the derrick, hoisting a prefabricated separator into position at the top of the derrick, attaching said separator to the top of the derrick, and connecting the lift pipe and feed leg to the bottom of the separator.

2. The method of erecting a simplified moving bed cracking system which comprises erecting a well derrick comprised `of frame means defining a space of a cross sectional area that decreases with height, attaching a gin pole to the top of the derrick, attaching a hook to the gin pole, attaching substantially horizontal supporting means to the derrick in the lower section thereofadapted to support a first vessel, stiff-legging at least one of the legs of the derrick up to the level of said horizontal supporting means, introducing a rst prefabricated vessel through one of said frames near the bottom thereof, hoisting said first vessel within the derrick to said horizontal supporting l means by means of rigging attached to said hook, supporting said first vessel from said supporting means in one corner of the derrick, attaching a second substantially horizontal supporting means to the derrick in the lower section thereof adapted to support a second vessel, similarly introducing and hoisting said second vessel within the derrick to said second horizontal supporting means by means of rigging attached to said hook, supporting said second vessel from said horizontal support means in the same corner of the derrick as the first vessel at a level below the first vessel, locating a lift pot at the bottom of the derrick in a 'central location, building a lift pipe from prefabricated sections upwardly from the lift pot to a location at the top of the derrick, connecting the bottom of said first vessel and the top of the second vessel 7 with a communicating conduit, connecting the bottom of the second vessel and the lift pot with a communicating conduit, building a gravity feed leg above the first vessel to a location near the top of the derrick, hoisting a prefabricated separator into position at the top of the derrick,

'J5 attaching said separator to the top of the derrick and 7 Y 8 connecting the 'lift pipe and feed leg to the bottom of the 2,561,409 Afde'rn i.. July 24, 1951 separator. .K 2,562,903 1 'Fontana'. Q Aug. 3, 1951 References Cited in the le of this patent i i OTHER REFERENCES Recent Developments in TCC Processing, by Simpson UNITED STATES PATENTS o et jaL, presented Nov; Il, 1943, before the Refining Divi- 543,005* Fleischer July 23 1895 sion, American Petroleum Institute- 8 pages.

1,494,324 Owe May 13 1924 The Oil and Gas Journal, May 11, 1950, page 53. 2,304,354 Harvey Dec-v8: 1942 Houdry Pioneer,v vol. 3, No. 2, November 1948, 2,360,222 Greunmg et al Oct.` 10, 1944 Y 2,547,900 Bergstrom Apr.3,1'951 m page 3. 

2. THE METHOD OF ERECTING A SIMPLIFIED MOVING BED CRACKING SYSTEM WHICH COMPRISES ERECTING A WELL DERRICK COMPRISED OF FRAME MEANS DEFINING A SPACE OF A CROSS SECTIONAL AREA THAT DECREASES WITH HEIGHT, ATTACHING A GIN POLE TO THE TOP OF THE DERRICK, ATTACHING A HOOK TO THE GIN POLE, ATTACHING SUBSTANTIALLY HORIZONTAL SUPPORTING MEANS TO THE DERRICK IN THE LOWER SECTION THEREOF ADAPTED TO SUPPORT A FIRST VESSEL, STIFF-LEGGING AT LEAST ONE OF THE LEGS OF THE DERRICK UP TO THE LEVEL OF SAID HORIZONTAL SUPPORTING MEANS, INTRODUCING A FIRST PREFABRICATED VESSEL THROUGH ONE OF SAID FRAMES NEAR THE BOTTOM THEREOF, HOISTING SAID FIRST VESSEL WITHIN THE DERRICK TO SAID HORIZONTAL SUPPORTING MEANS BY MEANS OF RIGGING ATTACHED TO SAID HOOK, SUPPORTING SAID FIRST VESSEL FROM SAID SUPPORTING MEANS IN ONE CORNER OF THE DERRICK, ATTACHING A SECOND SUBSTANTIALLY HORIZONTAL SUPPORTING MEANS TO THE DERRICK IN THE LOWER SECTION THEREOF ADAPTED TO SUPPORT A SECOND VESSEL, SIMILARLY INTRODUCING AND HOISTING SAID SECOND VESSEL WITHIN THE DERRICK TO SAID SECOND HORIZONTAL SUPPORT MEANS BY MEANS OF RIGGING ATTACHED TO SAID HOOK, SUPPORTING SAID SECOND VESSEL FROM SAID HORIZONTAL SUPPORT MEANS IN THE SAME CORNER OF THE DERRICK AS THE FIRST VESSEL AT A LEVEL BELOW THE FIRST VESSEL, LOCATING A LIFT POT AT THE BOTTOM OF THE DERRICK IN A CENTRAL LOCATION, BUILDING A LIFT PIPE FROM PREFABRICATED SECTIONS UPWARDLY FROM THE LIFT POT TO A LOCATION AT THE TOP OF THE DERRICK, CONNECTING THE BOTTOM OF SAID FIRST VESSEL AND THE TOP OF THE SECOND VESSEL WITH A COMMUNICATING CONDUIT, CONNECTING THE BOTTOM OF THE SECOND VESSEL AND THE LIFT POT WITH A COMMUNICATING CONDUIT, BUILDING A GRAVITY FEED LEG ABOVE THE FIRST VESSEL TO A LOCATION NEAR THE TOP OF THE DERRICK, HOISTING A PREFABRICATED SEPARATOR INTO POSITION AT THE TOP OF THE DERRICK, ATTACHING SAID SEPARATOR TO THE TOP OF THE DERRICK AND CONNECTING THE LIFT PIPE AND FEED LEG TO THE BOTTOM OF THE SEPARATOR. 